Apparatus for use in the formation of a tobacco rod

ABSTRACT

An apparatus for the formation of machine-made tobacco rods for use in the production of cigars. The apparatus includes a lower conveyor belt and an upper compression belt for receiving and compressing the stream of tobacco, the lower conveyor belt and upper compression belt driven by a plurality of pulleys; a pair of squeeze bars for compressing the tobacco in a direction perpendicular to the pair of transfer and compression belts, the pair of squeeze bars coated with a poly-condensated silicone or a polymeric silazane finish; a tongue for receiving the compressed tobacco, the tongue coated with a poly-condensated silicone or a polymeric silazane finish; and a short folder for folding a wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars, the short folder coated with a poly-condensated silicone or a polymeric silazane finish.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S.Provisional Application No. 62/099,890 filed Jan. 5, 2015, the contentsof which are hereby incorporated by reference in their entirety.

FIELD

The present invention generally relates to the manufacture of smokingarticles, more specifically, cigar manufacturing and, in particular, toa method and apparatus for the formation of machine-made tobacco rodsfor use in the production of cigars.

ENVIRONMENT

In the manufacture of machine-made cigars, it is essential that tobaccobe utilized as efficiently as possible due to its relatively high cost.In modern cigar manufacturing, it is also desirable to closely controlthe quantity of tobacco contained in each cigar, so as to provide acigar that is considered well filled and is well filled on a consistentbasis.

The manufacture of machine-made cigars may present a further problemimpacting tobacco utilization, which relates to the particular tobaccoblend sought to be employed. Machine-made cigars produced frompipe-tobacco blends have achieved wide acceptance in the market place.However, pipe-tobacco blends may have a degree of tackiness impartedthereto by the flavorants and other additives employed to enhancesmoking enjoyment. The tacky, tobacco borne materials tend to stick toand accumulate along, guides, plows, garniture folding surfaces and thelike of tobacco rod forming machines and other tobacco handlingapparatus. Machines for making tobacco rods from pipe-tobacco blends areoften modified to increase the clearances between parts (such as betweena belt and a guide adjacent the belt) to accommodate the tackypipe-tobacco blends, increasing the likelihood that the tobacco willescape and be utilized less efficiently, with greater tobacco waste.

There is a need for an improved method and apparatus for the manufactureof tobacco products, including machine-made cigars from tacky tobaccos,which will provide satisfactory cigars and be efficient in the use oftobacco.

SUMMARY

In one aspect, provided is a method of decreasing tobacco waste duringthe formation of machine-made tobacco rods for use in the production ofcigars from tobacco having a tacky material combined therewith, Themethod includes the steps of providing a plurality of components of acigar rod-making machine, the plurality of components coated with apoly-condensated silicone or a polymeric silazane finish; and reducingat least one clearance gap between at least one of the plurality ofcomponents with an adjacent component of the cigar rod-making machine toreduce the amount of tobacco escaping through the gap.

In one form, the method further includes the step of operating the cigarrod-making machine to produce cigar rods from the tobacco having a tackymaterial combined therewith, wherein tobacco wasted in the production ofcigar rods is decreased.

In another form, the tobacco wasted in the production of cigar rods isdecreased by at least 25%.

In yet another form, the tobacco wasted in the production of cigar rodsis decreased by at least 50%.

In still yet another form, the tobacco wasted in the production of cigarrods is decreased by at least 80%.

In one form, the plurality of components include components havingsurfaces that contact the tobacco.

In a further form, the plurality of components are selected from a pairof squeeze bars (or guides or plows or rails) for compressing thetobacco, one or more pulleys for advancing transfer and/or compressionbelts, a tongue for guiding the tobacco, a short folder, or anycombination thereof.

In another aspect, provided is an apparatus for the formation ofmachine-made tobacco rods for use in the production of cigars fromtobacco having a tacky material combined therewith. The apparatusincludes a lower conveyor belt and an upper compression belt forreceiving and compressing the stream of tobacco, the lower conveyor beltand upper compression belt driven by a plurality of pulleys; a pair ofsqueeze bars for compressing the tobacco in a direction perpendicular tothe pair of transfer and compression belts, the pair of squeeze barscoated with a poly-condensated silicone or a polymeric silazane finish;a tongue for receiving the compressed tobacco, the tongue coated with apoly-condensated silicone or a polymeric silazane finish; and a shortfolder for folding a wrapper material around the compressed tobacco soas to form a continuous rod of tobacco for use in the production ofcigars, the wrapper material provided from a source of wrapper material,the short folder coated with a poly-condensated silicone or a polymericsilazane finish.

In one form, each of the plurality of pulleys is coated with apoly-condensated silicone or a polymeric silazane finish.

In yet another form, the apparatus includes a second heater bar forfurther curing the glue and sealing the wrapper material to form thecontinuous rod of tobacco for use in the production of cigars.

In another aspect, provided is a method for the formation ofmachine-made tobacco rods for use in the production of cigars fromtobacco having a tacky material combined therewith. The method includesproviding a stream of tobacco in a substantially uniform format;receiving and compressing the stream of tobacco between a lower conveyorbelt and an upper compression belt, the lower conveyor belt and uppercompression belt driven and guided by a plurality of pulleys;compressing the tobacco in a direction perpendicular to the pair oftransfer and compression belts between a pair of squeeze bars, the pairof squeeze bars coated with a poly-condensated silicone or a polymericsilazane finish; conveying the compressed tobacco downstream to atongue, the tongue coated with a poly-condensated silicone or apolymeric silazane finish; providing a wrapper material from a source ofwrapper material; and folding the wrapper material around the compressedtobacco so as to form a continuous rod of tobacco for use in theproduction of cigars.

In one form, the step of folding the wrapper material around thecompressed tobacco so as to form a continuous rod of tobacco for use inthe production of cigars utilizes a short folder coated with apoly-condensated silicone or a polymeric silazane finish.

In another form, each of the plurality of pulleys is coated with apoly-condensated silicone or a polymeric silazane finish.

In yet another aspect, provided is a method of decreasing the waste of atacky shredded material in the machine formation of a formed body. Themethod comprises the steps of providing a plurality of forming machinecomponents, the plurality of components coated with a poly-condensatedsilicone or a polymeric silazane finish and characterized by aresistance to collecting the tacky shredded material and having a degreeof wear resistance; and reducing at least one clearance gap between atleast one of the plurality of components with an adjacent component ofthe forming machine to reduce the possibility that the tacky shreddedmaterial escapes through the gap.

In still yet another aspect, provided is a method of forming a rod froma shredded material and a wrapper, the shredded material including atacky constituent, the method comprising: establishing a moving columnof the shredded material; compressing the column by moving the columnalong opposing converging guides coated with a poly-condensated siliconeor a polymeric silazane finish; forming the rod by drawing thecompressed column and the wrapper through a folding surface coated witha poly-condensated silicone or a polymeric silazane finish.

In one form, the step of establishing includes moving a lower endlessbelt adjacent a feeder while guiding the lower belt with a guide platecoated with a poly-condensated silicone or a polymeric silazane finish.

In another form, the step of compressing includes compressing the columnwith convergent, opposing endless belts.

In still another form, the method includes the step of abatingaccumulation of shredded material by providing a guide piece coated witha poly-condensated silicone or a polymeric silazane finish at atransition space between sets of convergent, opposing endless belts.

In a further aspect, provided is an apparatus capable of forming a rodfrom a shredded material and a wrapper, the shredded material includinga tacky constituent. The apparatus includes a feeder that establishes amoving column of the shredded material; opposing converging guides thatcompress the column as the column moves along the opposing convergingguides, the opposing converging guides coated with a poly-condensatedsilicone or a polymeric silazane finish; a folding surface that formsthe rod as the compressed column and the wrapper are drawn through thefolding surface, the folding surface coated with a poly-condensatedsilicone or a polymeric silazane finish.

In one form, the feeder includes moving a lower endless belt and a guideplate that guides the lower endless belt, the guide plate coated with apoly-condensated silicone or a polymeric silazane finish.

In another form, the opposing converging guides cooperate withconvergent, opposing endless belts to compress the column.

In still another form, the apparatus further includes a transition guideat a transition space between sets of convergent, opposing endlessbelts, the transition guide abating accumulation of shredded materialand coated with a poly-condensated silicone or a polymeric silazanefinish.

BRIEF DESCRIPTION OF THE DRAWINGS

The forms disclosed herein are illustrated by way of example, and not byway of limitation, in the figures of the accompanying drawings and inwhich like reference numerals refer to similar elements and in which:

FIG. 1a schematically presents an apparatus for the formation ofmachine-made tobacco rods, in accordance herewith;

FIG. 1b is a side planar view of squeeze bar 60, as shown in FIG. 1 b;

FIG. 2 is a cross-sectional view taken through section 2-2 of FIG. 1 a;

FIG. 3 schematically presents a top view of the in-feed section of anapparatus for the formation of machine-made tobacco rods for use in theproduction of cigars, in accordance herewith;

FIG. 4 presents an exploded view of Section A of FIG. 1 a;

FIG. 5 is a cross-sectional view taken through Section 5-5 of FIG. 1 a;

FIG. 6 is a cross-sectional view taken through Section 6-6 of FIG. 1a ;and

FIGS. 7-10 present cross-sectional views of a tobacco rod as itprogresses through the folding or rolling operation.

DETAILED DESCRIPTION

Various aspects will now be described with reference to specific formsselected for purposes of illustration. It will be appreciated that thespirit and scope of the apparatus, system and methods disclosed hereinare not limited to the selected forms. Moreover, it is to be noted thatthe figures provided herein are not drawn to any particular proportionor scale, and that many variations can be made to the illustrated forms.Reference is now made to FIGS. 1-10, wherein like numerals are used todesignate like elements throughout.

Each of the following terms written in singular grammatical form: “a,”“an,” and “the,” as used herein, may also refer to, and encompass, aplurality of the stated entity or object, unless otherwise specificallydefined or stated herein, or, unless the context clearly dictatesotherwise. For example, the phrases “a device,” “an assembly,” “amechanism,” “a component,” and “an element,” as used herein, may alsorefer to, and encompass, a plurality of devices, a plurality ofassemblies, a plurality of mechanisms, a plurality of components, and aplurality of elements, respectively.

Each of the following terms: “includes,” “including,” “has,” “having,”“comprises,” and “comprising,” and, their linguistic or grammaticalvariants, derivatives, and/or conjugates, as used herein, means“including, but not limited to.”

Throughout the illustrative description, the examples, and the appendedclaims, a numerical value of a parameter, feature, object, or dimension,may be stated or described in terms of a numerical range format. It isto be fully understood that the stated numerical range format isprovided for illustrating implementation of the forms disclosed herein,and is not to be understood or construed as inflexibly limiting thescope of the forms disclosed herein.

Moreover, for stating or describing a numerical range, the phrase “in arange of between about a first numerical value and about a secondnumerical value,” is considered equivalent to, and means the same as,the phrase “in a range of from about a first numerical value to about asecond numerical value,” and, thus, the two equivalently meaning phrasesmay be used interchangeably.

It is to be understood that the various forms disclosed herein are notlimited in their application to the details of the order or sequence,and number, of steps or procedures, and sub-steps or sub-procedures, ofoperation or implementation of forms of the method or to the details oftype, composition, construction, arrangement, order and number of thesystem, system sub-units, devices, assemblies, sub-assemblies,mechanisms, structures, components, elements, and configurations, and,peripheral equipment, utilities, accessories, and materials of forms ofthe system, set forth in the following illustrative description,accompanying drawings, and examples, unless otherwise specificallystated herein. The apparatus, systems and methods disclosed herein canbe practiced or implemented according to various other alternative formsand in various other alternative ways.

It is also to be understood that all technical and scientific words,terms, and/or phrases, used herein throughout the present disclosurehave either the identical or similar meaning as commonly understood byone of ordinary skill in the art, unless otherwise specifically definedor stated herein. Phraseology, terminology, and, notation, employedherein throughout the present disclosure are for the purpose ofdescription and should not be regarded as limiting.

As can be the case in the manufacture of certain machine-made cigars,the tobacco may have a tacky material combined therewith prior to rodformation, such as by way of addition of flavorants and other additives.Examples of suitable types of tobaccos that may be used in themanufacture of machine-made cigars include, but are not limited to,flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco,rare tobacco, specialty tobacco, reconstituted tobacco, blends thereofand the like. Optionally, the tobacco may be pasteurized. In thealternative, the tobacco material may be fermented.

Suitable flavorants and aromas include, but are not limited to, anynatural or synthetic flavor or aroma, such as tobacco, smoke, menthol,mint (such as peppermint and spearmint), chocolate, licorice, citrus andother fruit flavors, gamma octalactone, vanillin, ethyl vanillin, breathfreshener flavors, spice flavors such as cinnamon, methyl salicylate,linalool, bergamot oil, geranium oil, lemon oil, and ginger oil. Othersuitable flavors and aromas may include flavor compounds selected fromthe group consisting of an acid, an alcohol, an ester, an aldehyde, aketone, a pyrazine, combinations or blends thereof and the like.Suitable flavor compounds may be selected, for example, from the groupconsisting of phenylacetic acid, solanone, megastigmatrienone,2-heptanone, benzylalcohol, cis-3-hexenyl acetate, valeric acid, valericaldehyde, ester, terpene, sesquiterpene, nootkatone, maltol,damascenone, pyrazine, lactone, anethole, iso-valeric acid, combinationsthereof and the like.

Exemplary additional natural and artificial flavorants include, but arenot limited to, peppermint, spearmint, wintergreen, menthol, cinnamon,chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, roseoil, vanilla, lemon oil, cassia, fennel, ginger, ethylacetate,isoamylacetate, propylisobutyrate, isobutyl butyrate, ethylbutyrate,ethylvalerate, benzylformate, limonene, cymene, pinene, linalool,geraniol, citronellol, citral, orange oil, coriander oil, borneol, fruitextract, and the like. Particularly preferred additional flavor andaroma agents are essential oils and/or essences of coffee, tea, cacao,and mint.

Humectants can also be added to the tobacco material to help maintainthe moisture levels. Examples of humectants that can be used with thetobacco include glycerol and propylene glycol. It is noted that thehumectants can also be provided for a preservative effect, as the wateractivity of the product can be decreased with inclusion of a humectant,thus reducing opportunity for growth of micro-organisms. Additionally,humectants can be used to provide a higher moisture feel to a driertobacco component.

In one form, the tobacco used in the manufacture of machine-made cigarsemploying the apparatus and methods disclosed herein is a pipe tobaccoblend having a degree of tackiness imparted thereto.

Referring to FIG. 1, an apparatus 10 for the formation of machine-madetobacco rods is schematically presented. Advantageously, apparatus 10 isparticularly useful in the production of cigars from tobacco having atacky material combined therewith. One such application is theproduction of cigars from a form of pipe tobacco.

As shown, apparatus 10 includes a tobacco feed section 12, an in-feedsection 14 and a finishing section 16. Tobacco feed section 12 mayinclude at least one conveyer (not shown) for receiving the stream oftobacco from a source of tobacco. Tobacco feed section 12 may alsoinclude at least one electromagnetic vibrator (not shown) for providingthe stream of tobacco in a substantially uniform format. Suitableelectromagnetic vibrators 18 are available from Eriez Corporation ofErie, Pa. and possess the ability provide for the relatively high speedfeeding of light, bulky materials.

In one form, in-feed section 12 may be constructed from existingequipment, such as an in-feed section of an AMF cigarette makingmachine. Finishing section 16 may also be constructed from existingequipment, such as a Molins Mk 8 or Mk 9 machine, available from MolinsPLC of Milton Keynes, UK.

Referring still to FIG. 1, in one form, a vibratory waterfall feeder 20is positioned downstream of the tobacco feed section 12 for receivingthe stream of tobacco. Vibratory waterfall feeder 20 feeds tobacco to anin-feed section 14, establishing a column of tobacco along lowerconveyor belt 24, which is driven and guided by a plurality of pulleys26. The lower conveyor belt 24 is kept in tension by a biased tensionpulley 28. The stream of tobacco may optionally proceed past a trimmerunit 22, to establish a uniform height along the column of tobaccoestablished atop the lower conveyor belt 24 by the vibratory waterfallfeeder 20.

Referring now to FIG. 2, a view of apparatus 10 taken through Section2-2 is presented. As shown, lower conveyor belt 24 rides above aconveyor guide 70, the conveyor guide 70 being positioned withinconveyer base plate 72. Tobacco T from vibratory waterfall feeder 20 isdeposited upon lower conveyor belt 24. A first trough member 74 and asecond trough member 76 guide the tobacco T onto the lower conveyor belt24. First trough member 74 is affixed to a first angle bracket 78 andsecond trough member 76 is affixed to a second angle bracket 80. Asshown, first angle bracket 78 and second angle bracket 80 may extendover a portion of lower conveyor belt 24 so as to maintain the positionof lower conveyor belt 24 within conveyer base plate 72.

Referring again to FIG. 1, in one form, the in-feed section 14 includesan upper (compression) belt 50 positioned downstream of vibratorywaterfall feeder 20, above and in opposing relation with at least aportion of lower conveyor belt 24 and is likewise disposed with at leasta portion of transfer or garniture tube belt 42. Upper compression belt50 and a portion of transfer or garniture tube belt 42 are configured toreceive and compress the stream of tobacco. Compression belt 50 isdriven and guided by a plurality of pulleys 52 and is kept in tension bya tension pulley 54.

Referring also to FIG. 3, squeeze bars 60 and 62 are provided in amutually opposing, converging relation for compressing the tobacco in atransverse direction (side to side), while also compression belt 50 andlower conveyor belt 24 are in a mutually opposing, converging relationfor compressing the tobacco from top to bottom of the tobacco column. Atthe furthest end of lower conveyor belt 24, the tobacco column istransferred from lower conveyor belt 24 onto a binder web 30, which issupplied from a source of binder web 32. Binder web 30 is mated withwrapper web 34, which is supplied from a source of wrapper web 36, andis supported and drawn by a transfer or garniture tube belt 42. In theembodiments, the binder web 30 and the wrapper web 34 comprise tobacco.

Referring now to FIG. 4, an exploded schematic view of Section A of FIG.1 is presented. As shown, in one form, a transition piece 56 is employedto bridge the transition from lower conveyor belt 24 to transfer orgarniture tube belt 42, creating a smoother path for a tobacco column totraverse. Additionally, the transition piece 56 serves to reduce thelevel of turbulence that might otherwise be imparted to a tobacco columntraversing the transition from lower conveyor belt 24 to transfer orgarniture tube belt 42. The transition piece 56 occupies space at thetransition between belts 24 and 42, which space would otherwise allowtobacco to accumulate and intermittently release, with impact on productconsistency.

Referring again to FIG. 1, the formation of the tobacco column will bedescribed in more detail. As the tobacco stream enters the arrangementformed by the pair of squeeze bars 60 and 62, lower conveyor belt 24,and upper compression belt 50, the cross-sectional area of thearrangement is continuously reduced, forcing the tobacco to becompressed into an ever-smaller cross-section, until it reaches thedesired cross-sectional dimension. Referring to FIG. 5, across-sectional view of Section 5-5 of FIG. 1 is presented. As may beseen a cross-sectional-area is formed by the arrangement formed bysqueeze bars 60 and 62, lower conveyor belt 24, and upper compressionbelt 50. Moving along apparatus 10 to Section 6-6 of FIG. 1, referenceis made to FIG. 6, wherein a reduced cross-sectional-area is depicted.As one of ordinary skill in the art would recognize small clearances orgaps exist along the corners 25 of the arrangement.

The column of tobacco proceeds to finishing section 16 is guided througha rod-forming arrangement 40, which includes a tongue 58. Rod-formingarrangement 40 is configured and arranged to fold the binder and wrapperweb 30 and 34, respectively, longitudinally around the tobacco columnand, in one form, employs a first garniture or short folder 64 and asecond or finishing folder 66 for folding the wrapper web around thecompressed tobacco column so as to form a continuous rod of tobacco foruse in the production of cigars, the wrapper web provided from a sourceof wrapper material. An adhesive, which may be an adhesive such as PVA,is applied by adhesive applicator 59 to one lap edge of the wrapper web34, and seals the lap joint by applying heat, by at least one heater 67to set the adhesive.

To further demonstrate the folding or rolling operation, reference ismade to FIG. 1 and to FIGS. 7-10, where cross-sections of a tobacco rodare presented to show the relative state of wrapper/binder folding orrolling at various positions along the length of rod-forming arrangement40. As shown in FIG. 7, taken at Section 7-7 of FIG. 1 at the entranceto tongue 63, the folding process has yet to begin. As shown in FIG. 8,taken at Section 8-8 of FIG. 1 at the entrance to short folder 64, thefolding operation has begun, with an upper lap edge of thewrapper/binder 30/34 extending substantially vertically and having hadan application of glue applied thereto by adhesive applicator 59.Referring now to FIG. 9, taken at Section 9-9 of FIG. 1 at the entranceto the second folder 66, it may be seen that one side of thewrapper/binder 30/34 has been fully rolled over, while the upper lapedge of the wrapper/binder 30/34 still extends substantially vertically.Referring now to FIG. 10, taken at Section 10-10 of FIG. 1 at the exitof second folder 66, it may be seen that the tobacco rod has been fullyformed and ready for heating to set the glue applied by adhesiveapplicator 67.

A continuous rod is thus produced and is carried by the garniture tubebelt 42 through an optional air bearing arrangement (not shown). The rodthen emerges from the garniture tube belt 42 and may pass through aweight scanner (not shown) and then through a diameter gauge (not shown)before being cut into discrete rod lengths by a cutter 68.

When forming tobacco rods, particularly when the tobacco is of the typefrequently marketed as pipe tobacco, the tobacco tends to accumulate onthe machine surfaces. In manufacturing operations, to mitigate theproblems associated with this accumulation, opposing parts were designedto have greater clearances greater than a nominal clearance, whichpermitted the escape of tobacco during machine operation. The extraclearances allowed great amounts of tobacco to escape.

It has been discovered that the use of a hard ceramic coating that isheat stable, durable, and which also has a degree of wear resistance, tocoat the parts of the rod making apparatus that come into contact withtobacco, reduces or eliminates tobacco accumulation on machine partshaving surfaces that come into contact with tobacco, permitting closerclearances to be employed between many of the parts, includingclearances 25, as shown in FIG. 5. Previously, clearances suchclearances 25 were set to a dimension on the order of about 0.100inches. Advantageously, the application of the hard ceramic coatingdisclosed herein permit the setting of such clearances to values ofabout 20 percent of their previous values, such as in this example toabout 0.020 inches.

As may be appreciated, closer clearances enable improved tobaccoutilization, since the escape of tobacco is reduced or minimized duringthe rod making operation. In operation, the resultant rod making machineis cleaner, faster, more consistent, more flexible, and more efficientthan prior designs. As may be appreciated, such advantages can lead tothe production of higher quality product.

One coating that has been developed is a non-stick ceramicpoly-condensated silicone coating using an inorganic network of metalalkoxides and an organic network of polysilanes. Typically, the coatingis applied using a sol-gel process. This coating is typically applied intwo layers, where the base or first layer is typically a combination ofpolydimethylsiloxane in a matrix of mixed materials includingorganoalkoxysilane, silica sol and an alcoholic solvent. The secondlayer is usually applied to further enhance the non-stick properties,and change the surfaces color, by including fluoroalkoxysilanes alongwith polydimethylsiloxane and the matrix of mixed materials listedabove. Such coatings are commercially available from Thermolon, Ltdunder the trademark Thermolon™ and come in a number of varietiesdepending on the combination of polydimethylsiloxane,flouoalkoxysilanes, and the matrix materials. Thermolon™ coatings cangenerally withstand temperatures up to 750 degrees Fahrenheitindefinitely without any serious loss of performance.

Another coating having utility in the practice of the present inventionis a polyceramic coating containing both polymeric and ceramiccomponents to enable hard, durable surfaces with excellent releaseproperties. A common tradename for one such product is Cerakote™, soldby NIC, where the polyceramic materials is mixed into a solvent and thenapplied as a sol-gel via spraying, brushing or wiping. Another suchproduct is sold under the Ceraset™ trade name by KiON International.This type of coating is commonly used on products such as gun barrels,which also desire good release properties.

In one embodiment, the coating generally is comprised of apoly-condensated silicone or a polymeric silazane finish (commonlycalled Thermolon™) or a poly-ceramic finish (commonly branded underCeraset™ and Cerakote™ brands). In alternate embodiments, the coatingcan include any suitable heat stable coating that is uncommonly hard,provides outstanding release properties and will adhere to the surfacesthat come in contact with tobacco of a rod forming machine, as describedherein.

Thermolon™ possesses excellent mechanical and chemical resistanceproperties that are retained to high temperatures. For example,Thermolon™ retains a tensile hardness value of 9 H, even up to 200° C.(or above). Additionally, the abrasion resistance of Thermolon™(Reciprocal Abrasion Test; BS7069: 1988; 4.5 kg force; 3M 7447Scotch-Brite abrasive pad) is excellent and has been found to withstand32,000-59,000 cycles, depending upon the particular formulation. It ishighly resistant to thermal degradation as well as attack by bothorganic and aqueous environments.

In one form, components having surfaces that contact the tobacco arecoated with a material comprising a poly-condensated silicone or apolymeric silazane finish.

In one form, squeeze bars 60 and 62 are coated with a materialcomprising a poly-condensated silicone or a polymeric silazane finish.In another from, tongue 58 is also coated with a material comprising apoly-condensated silicone or a polymeric silazane finish. In stillanother form, transition piece 56 is also coated with a materialcomprising a poly-condensated silicone or a polymeric silazane finish.In still yet another form, short folder 64 and, optionally, a secondfolder 66 for folding a wrapper material around the compressed tobaccoso as to form a continuous rod of tobacco are coated with a materialcomprising a poly-condensated silicone or a polymeric silazane finish.With respect to the foregoing, the poly-condensated silicone orpolymeric silazane finish may be utilized along surfaces that come intocontact with tobacco.

It is contemplated that additional components of apparatus 10 may becoated with a poly-condensated silicone or a polymeric silazane finish.For example, the vibratory waterfall feeder 20 and/or the tobacco feedsection 12 may be coated with a poly-condensated silicone or a polymericsilazane finish. In some embodiments, the conveyor belt guide 70, whichlower conveyor belt 24 rides along, may also be coated with apoly-condensated silicone or a polymeric silazane finish. In addition,it is contemplated that the transition piece 56 (see FIG. 4) be coatedwith a poly-condensated silicone or a polymeric silazane finish. Use ofwith a poly-condensated silicone or a polymeric silazane finish alongthe conveyor belt guide 70 avoids accumulation of material between theconveyor belt guide 70 and the belt 24, which can otherwise lead tojamming of the belt. The belt has the tendency to pick up minute piecesof tobacco during its course of travel.

In one form, apparatus 10 employs a programmable logic controller (PLCunit) to control the formation of machine-made tobacco rods. SuitablePLC units are available from a number of sources, includingAllen-Bradley, a division of Rockwell Automation of Milwaukee, Wis.Vibratory waterfall feeder 20 is fed by a metering belt (not shown)which may be adjusted proportionally to the rod-making speed by signalsreceived by PLC unit. In one form, there is a sensor provided to monitorrod-making speed and the PLC unit is programmed to dynamically adjustthe metering belt in response to changes in rod-making speed.

Various signals, which may include a signal representing the roddiameter, an indication of the tobacco temperature obtained from atemperature sensor that may be located in a tobacco hopper, or in thechamber near the trimmer are fed to the PLC unit. Suitable rod diametergauges may be as described in U.S. Pat. No. 2,952,262, the contents ofwhich are hereby incorporated by reference in their entirety.

In operation, a tobacco column is carried on the gravity conveyor 24 anddrawn by the lower and upper belts 24 and 50, respectively. betweensqueeze bars 60 and 62 to garniture tube belt 42. A signal indicative ofthe firmness of the finished rod may be used to control the trimmerheight preferably after correction to compensate for moisture variationsso that the trimmer is controlled in response to the “dry firmness.” Acontrol motor may drive the trimmer up and down around an averagetrimmer height H_(avg), in response to control signals from themicroprocessor 66. The actual height H of the trimmer, determined by atrimmer position sensor (not shown), is fed to the PLC unit to provide asignal corresponding to the actual resistance of the part of the fillercolumn that remains after trimming.

From the data received, the PLC unit may calculate characteristics ofthe finished product and display such information on a display unit. PLCunit and display unit may be housed within a cabinet, which may alsoinclude a control panel, the combination of which forms a controlsystem. The control panel may provide the ability to control variousfunctions, including the heaters, glue applicator, machine start-up,system power, etc. Suitable control systems may be obtained from JewettAutomation of Richmond, Va. In one form, control system is a JewettAutomation Model Q75.

Alternatively, or in addition, information can be fed to a centralmanagement control system either for instant display or for storage, orfor both.

Additionally details concerning process controls and control schemesuseful in the operation and control of apparatus 10 are provided in U.S.Pat. No. 4,567,752, the contents of which are hereby incorporated byreference in their entirety.

In another aspect, provided is a method for the formation ofmachine-made tobacco rods for use in the production of cigars fromtobacco having a tacky material combined therewith. The method includesproviding a stream of tobacco in a substantially uniform format;receiving and compressing the stream of tobacco between a pair oftransfer and compression belts, the transfer and compression driven by aplurality of pulleys; compressing the tobacco in a directionperpendicular to the pair of transfer and compression belts between apair of squeeze bars, the pair of squeeze bars coated with apoly-condensated silicone or a polymeric silazane finish; conveying thecompressed tobacco downstream to a tongue, the tongue coated with apoly-condensated silicone or a polymeric silazane finish; providing awrapper material from a source of wrapper material; and folding thewrapper material around the compressed tobacco so as to form acontinuous rod of tobacco for use in the production of cigars.

In one form, the step of folding the wrapper material around thecompressed tobacco so as to form a continuous rod of tobacco for use inthe production of cigars utilizes a short folder coated with apoly-condensated silicone or a polymeric silazane finish. In anotherform, each of the plurality of pulleys is coated with a poly-condensatedsilicone or a polymeric silazane finish.

In one aspect, provided is a method of decreasing tobacco waste duringthe formation of machine-made tobacco rods for use in the production ofcigars from tobacco having a tacky material combined therewith, Themethod includes the steps of coating a plurality of components of acigar rod-making machine with a poly-condensated silicone or a polymericsilazane finish; reducing at least one gap between at least one of theplurality of components with an adjacent component of the cigarrod-making machine to reduce the possibility that the tobacco escapesthrough the gap.

In one form, the method further includes the step of operating the cigarrod-making machine to produce cigar rods from the tobacco having a tackymaterial combined therewith, wherein tobacco wasted in the production ofcigar rods is decreased.

In another form, the tobacco wasted in the production of cigar rods isdecreased by at least 25%. In yet another form, the tobacco wasted inthe production of cigar rods is decreased by at least 50%. In still yetanother form, the tobacco wasted in the production of cigar rods isdecreased by at least 80%. Tobacco waste is reduced by decreasingtolerance gaps between components coated with a poly-condensatedsilicone or a polymeric silazane finish by at least 20%, or at least30%, or at least 40% or more.

In a further form, the plurality of components are selected from a pairof squeeze bars for compressing the tobacco, one or more pulleys foradvancing transfer and/or compression belts, a tongue for guiding thetobacco, a short folder, or any combination thereof.

Examples

Testing was conducted to evaluate the productivity over an extendedperiod of time for an apparatus designed in accordance herewith. Thefocus of the evaluation was on machine runtime v. downtime, material andfiller waste and non-conforming product. Performance was assessed withrespect to productivity (e.g.: target rod weight, speed in rods perminute, production in terms of trays of product and machine interferencedowntime).

Performance was assessed with respect to waste and non-conformingproduct (e.g.: loose wrapper and binder, loose filler, long-ends (i.e.,rod-outs) and wrapper and binder cores).

The evaluation was conducted with the inventive rod maker and controlrod maker producing product to a target rod weight of 3,300 mg. Theinventive rod maker was running at a speed of 1,100 cigars per minutewhile the control rod maker was operating at a speed of 800 cigars perminute.

Notable causes of machine downtime during the evaluation include: tongueadjustments, a blade break and change, and cleaning of cutter gears.

As noted above, waste was collected from the inventive rod maker and acontrol rod maker.

As indicated above, the use of Thermolon™ to coat critical parts hasbeen found to permit the establishment of tighter part-to-partclearances, minimizing the escape of tobacco during the rod formationoperation. Thus, through material selection and the setting of properclearances, together with the integration of a PLC control system,improved performance was achieved.

While the present inventions have been described in connection with anumber of exemplary forms, and implementations, the present inventionsare not so limited, but rather cover various modifications, andequivalent arrangements, which fall within the purview of the presentclaims. For example, it is contemplated that the subject matterdisclosed herein would have utility in the formation of any wrapped orformed body produced from a tacky shredded material, such as shreddedherbal material, pouches of tacky shredded material, moist snuff or thelike.

What is claimed:
 1. In the formation of machine-made tobacco rods foruse in the production of smoking articles from a tobacco having a tackymaterial combined therewith, a method of decreasing tobacco waste,comprising the steps of: a) providing a plurality of components of arod-making machine, the plurality of components coated with apoly-condensated silicone or a polymeric silazane finish; and b)reducing at least one clearance gap between at least one of theplurality of components with an adjacent component of the rod-makingmachine to reduce the amount of tobacco escaping through the gap.
 2. Themethod of claim 1, further comprising the step of: c) operating therod-making machine to produce rods from the tobacco having a tackymaterial combined therewith, wherein tobacco wasted in the production ofcigar rods is decreased.
 3. The method of claim 2, wherein tobaccowasted in the production of cigar rods is decreased by at least 25%. 4.The method of claim 3, wherein tobacco wasted in the production of cigarrods is decreased by at least 50%.
 5. The method of claim 4, whereintobacco wasted in the production of cigar rods is decreased by at least80%.
 6. The method of claim 2, wherein the plurality of components areselected from those components having surfaces that contact the tobacco.7. The method of claim 6, wherein the plurality of components areselected from a pair of squeeze bars for compressing the tobacco, one ormore pulleys for advancing transfer and/or compression belts, a tonguefor guiding the tobacco, a short folder, a transition piece or anycombination thereof.
 8. The method of claim 6, wherein the plurality ofcomponents are selected from a vibratory waterfall feeder and/or atobacco feed section.
 9. An apparatus for the formation of machine-madetobacco rods for use in the production of cigars from tobacco having atacky material combined therewith, the apparatus comprising: (a) a lowerconveyor belt and an upper compression belt for receiving andcompressing the stream of tobacco, said lower conveyor belt and uppercompression belt driven by a plurality of pulleys; (b) a pair of squeezebars for compressing the tobacco in a direction perpendicular to saidpair of transfer and compression belts, said pair of squeeze bars coatedwith a poly-condensated silicone or a polymeric silazane finish; (c) atongue for receiving the compressed tobacco, said tongue coated with apoly-condensated silicone or a polymeric silazane finish; and (d) ashort folder for folding a wrapper material around the compressedtobacco so as to form a continuous rod of tobacco for use in theproduction of cigars, said wrapper material provided from a source ofwrapper material, said short folder coated with a poly-condensatedsilicone or a polymeric silazane finish.
 10. The apparatus of claim 9,further comprising a tobacco feed section for providing a stream oftobacco in a substantially uniform format.
 11. The apparatus of claim10, further comprising a vibratory waterfall feeder positioneddownstream of said tobacco feed section for receiving the stream oftobacco from said tobacco feed section.
 12. The apparatus of claim 11,wherein the vibratory waterfall feeder and/or the tobacco feed sectionare coated with a poly-condensated silicone or a polymeric silazanefinish.
 13. The apparatus of claim 9, wherein each of said plurality ofpulleys are coated with a poly-condensated silicone or a polymericsilazane finish.
 14. The apparatus of claim 13, further comprising asource of binder material for wrapping the compressed tobacco prior tofurther wrapping with the wrapper material.
 15. The apparatus of claim10, further comprising a glue applicator for applying glue to thewrapper material prior to folding the wrapper material around thecompressed tobacco.
 16. A method for the formation of machine-madetobacco rods for use in the production of cigars from tobacco having atacky material combined therewith, the method comprising: (a) providinga stream of tobacco in a substantially uniform format; (b) receiving andcompressing the stream of tobacco between a lower conveyor belt and anupper compression belt, the lower conveyor belt and upper compressionbelt driven and guided by a plurality of pulleys; (c) compressing thetobacco in a direction perpendicular to the pair of transfer andcompression belts between a pair of squeeze bars, the pair of squeezebars coated with a poly-condensated silicone or a polymeric silazanefinish; (d) conveying the compressed tobacco downstream to a tongue, thetongue coated with a poly-condensated silicone or a polymeric silazanefinish; (e) providing a wrapper material from a source of wrappermaterial; and (f) folding the wrapper material around the compressedtobacco so as to form a continuous rod of tobacco for use in theproduction of cigars.
 17. The method of claim 16, wherein said step offolding the wrapper material around the compressed tobacco so as to forma continuous rod of tobacco for use in the production of cigars utilizesa short folder coated with a poly-condensated silicone or a polymericsilazane finish.
 18. The method of claim 16, wherein each of theplurality of pulleys are coated with a poly-condensated silicone or apolymeric silazane finish.
 19. The method of claim 16, wherein the stepof providing a stream of tobacco in a substantially uniform formatemploys a vibratory waterfall feeder and a tobacco feed section that arecoated with a poly-condensated silicone or a polymeric silazane finish.20. In the machine formation of a formed body from a tacky shreddedmaterial, a method of decreasing the waste of the tacky shreddedmaterial, comprising the steps of: a) providing a plurality of formingmachine components, the plurality of components coated with apoly-condensated silicone or a polymeric silazane finish andcharacterized by a resistance to collecting the tacky shredded materialand having a degree of wear resistance; and b) reducing at least oneclearance gap between at least one of the plurality of components withan adjacent component of the forming machine to reduce the possibilitythat the tacky shredded material escapes through the gap.
 21. A methodof forming a rod from a shredded material and a wrapper, said shreddedmaterial including a tacky constituent, said method comprising:establishing a moving column of the shredded material; compressing saidcolumn by moving said column along opposing converging guides coatedwith a poly-condensated silicone or a polymeric silazane finish; formingthe rod by drawing said compressed column and the wrapper through afolding surface coated with a poly-condensated silicone or a polymericsilazane finish.
 22. The method of claim 21, wherein said establishingstep includes moving a lower endless belt adjacent a feeder whileguiding said lower belt with a guide plate coated with apoly-condensated silicone or a polymeric silazane finish.
 23. The methodof claim 22, wherein said compressing step includes compressing thecolumn with convergent, opposing endless belts.
 24. The method of claim23, further comprising abating accumulation of shredded material byproviding a guide piece coated with a poly-condensated silicone or apolymeric silazane finish at a transition space between sets ofconvergent, opposing endless belts.
 25. An apparatus capable of forminga rod from a shredded material and a wrapper, said shredded materialincluding a tacky constituent, said apparatus comprising: a feeder thatestablishes a moving column of the shredded material; opposingconverging guides that compress said column as said column moves alongsaid opposing converging guides, said opposing converging guides coatedwith a poly-condensated silicone or a polymeric silazane finish; afolding surface that forms the rod as said compressed column and thewrapper are drawn through said folding surface, said folding surfacecoated with a poly-condensated silicone or a polymeric silazane finish.26. The apparatus of claim 25, wherein said feeder includes moving alower endless belt and a guide plate that guides said lower endlessbelt, said guide plate coated with a poly-condensated silicone or apolymeric silazane finish.
 27. The apparatus of claim 26, wherein saidopposing converging guides cooperate with convergent, opposing endlessbelts to compress the column.
 28. The apparatus of claim 27, furthercomprising a transition guide at a transition space between sets ofconvergent, opposing endless belts, said transition guide abatingaccumulation of shredded material and coated with a poly-condensatedsilicone or a polymeric silazane finish.